Ultrasonically assisted turning of aviation materials: simulations and experimental study

Ultrasonically assisted turning of modern aviation materials is conducted with ultrasonic vibration (frequency f approximately 20 kHz, amplitude a approximately 15 microm) superimposed on the cutting tool movement. An autoresonant control system is used to maintain the stable nonlinear resonant mode of vibration throughout the cutting process. Experimental comparison of roughness and roundness for workpieces machined conventionally and with the superimposed ultrasonic vibration, results of high-speed filming of the turning process and nanoindentation analyses of the microstructure of the machined material are presented. The suggested finite-element model provides numerical comparison between conventional and ultrasonic turning of Inconel 718 in terms of stress/strain state, cutting forces and contact conditions at the workpiece/tool interface.     

超声辅助加工系统的刀具状态自感知算法

超声波振动台内含压电材料,可以拾取切削过程产生的振动信号,实现不借助外部传感器刀具工作状态的自感知。为了从刀具振动信号中获取有效信息,该文提出一种基于经验模态分解的时频域重构算法。首先,采用经验模态分解算法将原始信号分解,得到多个固有模态函数分量和残差分量;其次,计算原始信号与各分量之间的时频域互相关系数;再次,归一化时频域互相关系数作为权重值,将固有模态函数分量和残差进行重构;最后,通过数值仿真和超声辅助加工实验,验证了基于经验模态分解的时频域重构算法的去噪性能,提取了信噪比为5.03 dB的目标信号,从而实现了超声辅助加工系统的自感知功能。     

超声振动对光学玻璃加工的锯切力特征研究

超声振动辅助方法已在各种硬脆性材料的加工工艺中得以应用,其优异的加工能力和效果已得到广泛证明。本研究中通过采集有无超声振动条件下锯切光学玻璃的平均锯切力以及单颗金刚石磨粒划擦实验下的力信号,对不同工艺条件下的平均锯切力、单颗磨粒受力特征进行分析。同时通过扫描电镜观察对应力信号下工件与工具加工后表面形貌,进一步通过超声振动下材料去除机理解释超声振动对锯切力影响。结果表明：与传统锯切工艺相比,超声振动辅助使得单颗磨粒划擦过程中的受力降低引起平均锯切力的降低;超声振动改变普通锯切下材料的去除方式;同时可使工具保持良好的锯切状态,降低光学玻璃材料的锯切力比,改善其可加工性。     

Longitudinal ultrasonic vibration assisted guillotining of stacked paper

Ultrasonic vibration assisted cutting is a complex process with high dynamics. The interaction between cutting tool and workpiece is of key interest to understand the entire process. Experimental investigations are limited by the dynamics of the measurement system, and thus appropriately modeling of the ultrasonic vibration assisted cutting process is essential. In this investigation, a dynamic model regarding the ultrasonic vibration assisted guillotining of stacked paper sheets is developed. A Kelvin–Voigt material model, representing the individual sheets, is chosen, with its stiffness and damping parameters being empirically determined. A novel measurement strategy for studying the contact time and interaction between cutting tool and workpiece is introduced. It allows the verification of the highly dynamic behavior of the developed model. With the dynamic model, the experimentally observed cutting forces can be calculated. It is found that the dynamic forces cause a quicker failure of the material, which leads to a lower compression of the stack prior to reaching the critical cutting force.     

Theoretical and experimental investigations on rotary ultrasonic surface micro-machining of brittle materials

Many brittle materials, such as single-crystal materials, amorphous materials, and ceramics, are widely used in many industries such as the energy industry, aerospace industry, and biomedical industry. In recent years, there is an increasing demand for high-precision micro-machining of these brittle materials to produce precision functional parts. Traditional ultra-precision micro-machining can lead to workpiece cracking, low machined surface quality, and reduced tool life. To reduce and further solve these problems, a new micro-machining process is needed. As one of the nontraditional machining processes, rotary ultrasonic machining is an effective method to reduce the issues generated by traditional machining processes of brittle materials. Therefore, rotary ultrasonic micro-machining (RUμM) is investigated to conduct the surface micro-machining of brittle materials. Due to the small diameter cutting tool (<500 μm) and high accuracy requirements, the impact of input parameters in the rotary ultrasonic surface micro-machining (RUSμM) process on tool deformation and cutting quality is extremely different from that in rotary ultrasonic surface machining (RUSM) with relatively large diameter cutting tool (∼10 mm). Up till now, there is still no investigation on the effects of ultrasonic vibration (UV) and input variables (such as tool rotation speed and depth of cut) on cutting force and machined surface quality in RUSμM of brittle materials. To fill this knowledge gap, rotary ultrasonic surface micro-machining of the silicon wafer (one of the most versatile brittle materials) was conducted in this study. The effects of ultrasonic vibration, tool rotation speed, and depth of cut on tool trajectory, material removal rate (MRR), cutting force, cutting surface quality, and residual stress were investigated. Results show that the ultrasonic vibration could reduce the cutting force, improve the cutting surface quality, and suppress the residual compressive stress, especially under conditions with high tool rotation speed.     

超声变幅杆的超声精密加工

本文探讨了超声变幅杆的精密加工．作者研制了双刀反间进给超声车削装置和单刀正向进给超声车削装置，采用了具有频率跟踪系统的晶体营型超声波发生器．超声车削设备连续140min工作时，频率漂移量只有29HZ，最高温度只有38℃．试验结果表明，加工精度可达IT7－ITS，表面粗糙度几可达0．4－0．8m，加工效率提高15倍，有效地解决了超声变幅杆的精密加工难题．     

An approach based on tool mode control for surface roughness reduction in high-frequency vibration cutting

The presented research work, aimed at deeper understanding of vibrational process during high-frequency vibration cutting, is accomplished by treating cutting tool as an elastic structure which is characterized by several modes of natural vibrations. An approach for surface quality improvement is proposed in this paper by taking into account that quality of machined surface is related to the intensity of tool-tip (cutting edge) vibrations. It is based on the excitation of a particular higher vibration mode of a turning tool, which leads to the reduction of deleterious vibrations in the machine-tool-workpiece system through intensification of internal energy dissipation in the tool material. The combined application of numerical analysis with accurate finite element model as well as different experimental methods during investigation of the vibration turning process allowed to determine that the most favorable is the second flexural vibration mode of the tool in the direction of vertical cutting force component. This mode is excited by means of piezoelectric transducer vibrating in axial tool direction at the corresponding natural frequency, thereby enabling minimization of surface roughness and tool wear.     

一种曲线路径剪裁中刀具形变及其误差分析

动态移动切削阻力载荷对高速数控裁床加工过程中刀具形变及其剪裁误差具有的重要影响,提出了一种适用多层布料/皮革曲线剪裁路径的刀具形变及其误差计算方法;建立了动态负载条件下可伸缩刀具的挠度与转角方程,进而推导出高频振动裁刀剪裁误差及其随切削深度变化规律;计算结果表明,数控布料/皮革剪裁刀的动态载荷、高频振动参数、切削深度对剪裁误差具有重要影响,深入剖析高层数控裁床的加工机理,动态参数数据分析,对于提高机床加工效率,降低加工误差,提高刀具使用寿命具有一定的工程应用价值。     

基于ABAQUS的微细电火花超声振动主轴仿真研究

微细电火花技术凭借自身的特点和优势,在航空航天、医疗器械等领域发挥着重要的作用.超声振动辅助电火花加工在传统电火花加工中引入超声振动,加工精度和加工效率明显提高.作为核心部件,超声振动主轴的设计尤为重要.但传统设计过程,大大延长了研发周期和增加了成本,因此,采用仿真方式进行研究具有重要的意义.该文对设计的微细电火花超声...     

Numerical–experimental identification of the most effective dynamic operation mode of a vibration drilling tool for improved cutting performance

This study is concerned with application of numerical–experimental approach for characterizing dynamic behavior of the developed piezoelectrically excited vibration drilling tool with the aim to identify the most effective conditions of tool vibration mode control for improved cutting efficiency. 3D finite element model of the tool was created on the basis of an elastically fixed pre-twisted cantilever (standard twist drill). The model was experimentally verified and used together with tool vibration measurements in order to reveal rich dynamic behavior of the pre-twisted structure, representing a case of parametric vibrations with axial, torsional and transverse natural vibrations accompanied by the additional dynamic effects arising due to the coupling of axial and torsional deflections ((un)twisting). Numerical results combined with extensive data from interferometric, accelerometric, dynamometric and surface roughness measurements allowed to determine critical excitation frequencies and the corresponding vibration modes, which have the largest influence on the performance metrics of the vibration drilling process. The most favorable tool excitation conditions were established: inducing the axial mode of the vibration tool itself through tailoring of driving frequency enables to minimize magnitudes of surface roughness, cutting force and torque. Research results confirm the importance of the tool mode control in enhancing the effectiveness of vibration cutting tools from the viewpoint of structural dynamics.     

500 nm continuous wave tunable single-frequency mid-IR light source for C-H spectroscopy

A computer controlled tunable mid-IR light source, based on single resonant difference frequency generation (DFG), is experimentally investigated. The DFG process is pumped by an external cavity tapered diode laser, tunable over a spectral range of 30 nm. Grating feedback to the single mode channel of the tapered diode narrows the spectrum and allows for tuning of the emitted spectrum in the range from 780 to 810 nm. The DFG process takes place intra-cavity in a high finesse diode pumped 1064 nm solid state Nd:YVO₄ laser cavity, using periodically poled LiNbO₃ as the nonlinear material. Based on this new approach, a tunable single-frequency output power exceeding 3 mW was obtained in the mid-IR tuning range from 2.9 to 3.4 ??m.     

Condition monitoring of turning process using infrared thermography technique – An experimental approach

In metal cutting machining, major factors that affect the cutting tool life are machine tool vibrations, tool tip/chip temperature and surface roughness along with machining parameters like cutting speed, feed rate, depth of cut, tool geometry, etc., so it becomes important for the manufacturing industry to find the suitable levels of process parameters for obtaining maintaining tool life. Heat generation in cutting was always a main topic to be studied in machining. Recent advancement in signal processing and information technology has resulted in the use of multiple sensors for development of the effective monitoring of tool condition monitoring systems with improved accuracy. From a process improvement point of view, it is definitely more advantageous to proactively monitor quality directly in the process instead of the product, so that the consequences of a defective part can be minimized or even eliminated.In the present work, a real time process monitoring method is explored using multiple sensors. It focuses on the development of a test bed for monitoring the tool condition in turning of AISI 316L steel by using both coated and uncoated carbide inserts. Proposed tool condition monitoring (TCM) is evaluated in the high speed turning using multiple sensors such as Laser Doppler vibrometer and infrared thermography technique. The results indicate the feasibility of using the dominant frequency of the vibration signals for the monitoring of high speed turning operations along with temperatures gradient. A possible correlation is identified in both regular and irregular cutting tool wear. While cutting speed and feed rate proved to be influential parameter on the depicted temperatures and depth of cut to be less influential. Generally, it is observed that lower heat and temperatures are generated when coated inserts are employed. It is found that cutting temperatures are gradually increased as edge wear and deformation developed.     

Built-up edge investigation in vibration drilling of Al2024-T6

Adding ultrasonic vibrations to drilling process results in an advanced hybrid machining process, entitled “vibration drilling”. This study presents the design and fabrication of a vibration drilling tool by which both rotary and vibrating motions are applied to drill simultaneously. High frequency and low amplitude vibrations were generated by an ultrasonic transducer with frequency of 19.65 kHz. Ultrasonic transducer was controlled by a MPI ultrasonic generator with 3 kW power. The drilling tool and workpiece material were HSS two-flute twist drill and Al2024-T6, respectively. The aim of this study was investigating on the effect of ultrasonic vibrations on built-up edge, surface quality, chip morphology and wear mechanisms of drill edges. Therefore, these factors were studied in both vibration and ordinary drilling. Based on the achieved results, vibration drilling offers less built-up edge and better surface quality compared to ordinary drilling.     

Ultrasonic actuators for nanometre positioning

This paper deals with ultrasonic motors based on bimodal plate vibrations and their application to nanometre resolution stepper positioning systems. The concept of a linear ultrasonic motor drive capable of nanometric steps, long-range travel and reversible controlled motion is presented. The motor concept developed is based on the superposition of a longitudinal and bending vibrations of a rectangular resonator. The ultrasonic motor model based on system identification via discrete observations and prediction has been developed for control applications. The control algorithm for ultrasonic motors has been developed and theoretical investigations have been made. The open loop positioning system with designed stepper ultrasonic drive produced 10 nm resolution and 5% displacement repeatability. The system with computer controlled position feedback has shown 0.3 micron positioning accuracy over the 100 mm positioning range.     

Self-excited oscillation under nonlinear feedback with time-delay

Several important applications use nonlinear feedback methods for synthetically inducing self-excited oscillations in mechanical systems. The van der Pol and saturation function type feedback methods are widely used. The effects of time-delay on the self-excited oscillation of single and two degrees-of-freedom systems under nonlinear feedback have been studied in this paper. It is shown that a single degree-of-freedom oscillator with the van der Pol type nonlinear feedback can produce unbounded response in presence of time-delay. In general, an uncontrolled time-delay in the feedback changes the state of oscillations in an uncertain manner. Therefore, a bounded saturation type feedback with controllable time-delay is proposed for inducing self-excited oscillations. The feedback signal is essentially an infinite weighted sum of a nonlinear function of the state variables of the system measured at equal intervals in the past. More recent is the measurement, higher is the weight. Thus, the feedback signal uses a large amount of information about the past history of the dynamics. Such a control signal can be realized in practice by a recursive means. The control law allows three parameters to be varied namely, the time-delay, feedback and recursive gains. Multiple time scale analysis is used to plot amplitude vs. time-delay curves. Time-delay can be controlled to vary the amplitude of oscillation as well as to switch the oscillation from one mode to the other in a two degrees-of-freedom system. It is shown that a higher recursive gain can exercise a better and a more robust control on the amplitude of oscillation of the system. Analytical results are compared with the results of numerical simulations.     

A finite element model for ultrasonic cutting

Using a single-blade ultrasonic cutting device, a study of ultrasonic cutting of three very different materials is conducted using specimens of cheese, polyurethane foam and epoxy resin. Initial finite element models are created, based on the assumption that the ultrasonic blade causes a crack to propagate in a controlled mode 1 opening, and these are validated against experimental data from three point bend fracture tests and ultrasonic cutting experiments on the materials. Subsequently, the finite element model is developed to represent ultrasonic cutting of a multi-layered material. Materials are chosen whose properties allow a model to be developed that could represent a multi-layer food product or biological structure, to enable ultrasonic cutting systems to be designed for applications both in the field of food processing and surgical procedures. The model incorporates an estimation of the friction condition between the cutting blade and the material to be cut and allows adjustment of the frequency, cutting amplitude and cutting speed.     

Analysis of acoustic emission signals and monitoring of machining processes

Monitoring of a machining process on the basis of sensor signals requires a selection of informative inputs in order to reliably characterize and model the process. In this article, a system for selection of informative characteristics from signals of multiple sensors is presented. For signal analysis, methods of spectral analysis and methods of nonlinear time series analysis are used. With the aim of modeling relationships between signal characteristics and the corresponding process state, an adaptive empirical modeler is applied. The application of the system is demonstrated by characterization of different parameters defining the states of a turning machining process, such as: chip form, tool wear, and onset of chatter vibration. The results show that, in spite of the complexity of the turning process, the state of the process can be well characterized by just a few proper characteristics extracted from a representative sensor signal. The process characterization can be further improved by joining characteristics from multiple sensors and by application of chaotic characteristics.     

Rotary ultrasonic machining of CFRP: A mechanistic predictive model for cutting force

Cutting force is one of the most important output variables in rotary ultrasonic machining (RUM) of carbon fiber reinforced plastic (CFRP) composites. Many experimental investigations on cutting force in RUM of CFRP have been reported. However, in the literature, there are no cutting force models for RUM of CFRP. This paper develops a mechanistic predictive model for cutting force in RUM of CFRP. The material removal mechanism of CFRP in RUM has been analyzed first. The model is based on the assumption that brittle fracture is the dominant mode of material removal. CFRP micromechanical analysis has been conducted to represent CFRP as an equivalent homogeneous material to obtain the mechanical properties of CFRP from its components. Based on this model, relationships between input variables (including ultrasonic vibration amplitude, tool rotation speed, feedrate, abrasive size, and abrasive concentration) and cutting force can be predicted. The relationships between input variables and important intermediate variables (indentation depth, effective contact time, and maximum impact force of single abrasive grain) have been investigated to explain predicted trends of cutting force. Experiments are conducted to verify the model, and experimental results agree well with predicted trends from this model.     

超声辅助磨削杯形砂轮变幅器设计与试验*

超声辅助磨削在硬脆材料的加工中应用广泛。为研制以杯形砂轮为加工工具的超声辅助磨削主轴附件式工具系统,建立了杯形砂轮变幅器的理论模型,推导了其频率方程,并通过Matlab开发了杯形砂轮变幅器设计软件。利用该软件结合有限元分析对杯形砂轮变幅器进行了设计。将研制的杯形砂轮变幅器与BT40刀柄一体化外套筒、导电滑环装配组成了杯形砂轮超声辅助磨削主轴附件式工具系统。对该超声振动系统进行了阻抗分析试验及超声谐振试验,结果表明,该超声振动系统阻抗性能较好,能够使杯形砂轮产生稳定的超声振动,验证了所提出的设计方法的正确性,为主轴附件式超声磨削装置的设计提供了理论参考。     

High-frequency ultrasonic wire bonding systems

The vibration characteristics of longitudinal-complex transverse vibration systems with multiple resonance frequencies of 350-980 kHz for ultrasonic wire bonding of IC, LSI or electronic devices were studied. The complex vibration systems can be applied for direct welding of semiconductor tips (face-down bonding, flip-chip bonding) and packaging of electronic devices. A longitudinal-complex transverse vibration bonding system consists of a complex transverse vibration rod, two driving longitudinal transducers 7.0 mm in diameter and a transverse vibration welding tip. The vibration distributions along ceramic and stainless-steel welding tips were measured at up to 980 kHz. A high-frequency vibration system with a height of 20.7 mm and a weight of less than 15 g was obtained.